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PVG 120
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Danfoss PVG 120 Service guide

MAKING MODERN LIVING POSSIBLE
Service Manual
Proportional Valve Group
PVG 120
powersolutions.danfoss.com
Service Manual PVG 120 Proportional Valve Group
Revision history Table of revisions
Date Changed Rev
May 2014 Converted to Danfoss layout – DITA CMS, major revision JA
Feb 2011 Table on page 35 changed, layout changes - all pages IC
Feb 2010 Handles on drawings IA
Jan 2010 Japan location HC
2 520L0247 • Rev JA • May 2014
Service Manual
PVG 120 Proportional Valve Group

Contents

PVG 120 service parts exploded view PVG 120 sectional view Safety in application
Control system example................................................................................................................................................................ 8
Examples of wiring block diagram.....................................................................................................................................10
Identification
Identification ...................................................................................................................................................................................12
Installation
Installation and plug orientation..............................................................................................................................................13
Connection, PVP, Pump Side Module.....................................................................................................................................13
Oil flow direction............................................................................................................................................................................14
Tightening Torques.......................................................................................................................................................................14
PVM, Lever Positions.....................................................................................................................................................................16
Setting of max. flow...................................................................................................................................................................... 16
Pressure Setting..............................................................................................................................................................................17
PVP, LS Relief Valve Pressure Setting.................................................................................................................................17
PVB, LS Relief Valve Pressure Setting.................................................................................................................................17
Option, Oil Flow Direction and Setting of max Flow.........................................................................................................18
Installation of PVE.......................................................................................................................................................................... 18
Bleeding.............................................................................................................................................................................................20
PVPE/PVH relief valves................................................................................................................................................................. 20
PVPH and LS connections........................................................................................................................................................... 21
PVPE technical data.......................................................................................................................................................................21
Connection PVPE............................................................................................................................................................................22
PVP
PVP, Pump Side Module.............................................................................................................................................................. 23
PVPD, PVPH, PVPE, Accessories for PVP................................................................................................................................. 25
PVLP / PVLA
PVLP / PVLA, Shock and Suction Valve Port A/B................................................................................................................. 27
PVBP, PVBR, PVBC, PVBU
PVBP, PVBR, PVBC, PVBU Accessories for PVB......................................................................................................................29
PVM
PVM, Mechanical Activating Module......................................................................................................................................31
PVMD and PVH
PVMD, Cover for PVM and PVH, Hydraulic Activation...................................................................................................... 33
PVGI
PVGI, Interface for PVG 120 and PVG 32................................................................................................................................ 34
PVEH and PVEO
PVEH and PVEO, Electrical Activating Module, ON-OFF...................................................................................................35
PVT
PVT, Tank Side Module – Upper Part.......................................................................................................................................37
PVT, Tank Side Module – Lower Part.......................................................................................................................................39
PVAS and PVGI
PVGI, Assembly Kit.........................................................................................................................................................................41
PVAS, Assembly Kit........................................................................................................................................................................41
Asssembly sequence............................................................................................................................................................... 41
Set of seals
Set of Seals .......................................................................................................................................................................................43
PVG 120 Modules Selection Chart
PVG 120 module selection chart.............................................................................................................................................. 44
Order specification
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Service Manual PVG 120 Proportional Valve Group
Contents
Ordering of modules for oil flow exceeding 180 l/min [47.6 US gal/min].................................................................48
Order Form.......................................................................................................................................................................................48
Reordering...................................................................................................................................................................................49
4 520L0247 • Rev JA • May 2014
13
8
7
2
3
3
3
3
11
14
12
4
5
4
14
1
9
10
5
5
5
6
V310144.A
6
6
6
Service Manual PVG 120 Proportional Valve Group

PVG 120 service parts exploded view

PVG 120 service parts exploded view
520L0247 • Rev JA • May 2014 5
4
10 12 11
11
X-X
X
X
P A
V310100.A
9
2 1
T
P
T
p
ma
A B
A B
3
7 5 1 8
T
P
T
13
6
5
LS
T
P
T
3
13
P B
Service Manual PVG 120 Proportional Valve Group

PVG 120 sectional view

PVG 120 sectional view
Legend:
1 – Main spool 2 – Pressure adjustment spool in PVP 3 – Shuttle valve 4 – Pressure relief valve in PVP 5 – Pressure compensator in PVB 6 – LS pressure relief valve in PVB
7 – Shock and suction valve PVLP 8 – Suction valve PVLA 9 – Orifice, closed center PVP; Plug, open center PVP 10 – LS connection 11 – Orifice, open center PVP 12 – Plug, closed center PVP
6 520L0247 • Rev JA • May 2014
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Service Manual

Safety in application

PVG 120 Proportional Valve Group
All makes and all types of control valves (incl. proportional valves) can fail, thus the necessary protection against the serious consequences of function failure should always be built into the system. For each application an assessment should be made for the consequences of pressure failure and uncontrolled or blocked movements.
To determine the degree of protection that is required to be built into the application, system tools such an FMEA (Failure Mode and Effect Analysis) and Hazard and Risk Analysis can be used.
FMEA – IEC EN 61508
FMEA (Failure Mode and Effect Analysis) is a tool used for analyzing potential risks. This analytical technique is utilized to define, identify, and prioritize the elimination or reduction of known and/or potential failures from a given system before it is released for production. Please refer to IEC FMEA Standard 61508.
Hazard and risk analysis ISO 12100-1 / 14121
This analysis is a tool used in new applications as it will indicate whether there are special safety considerations to be met according to the machine directives EN 13849. Dependent on the determined levels conformity this analysis will detirmine if any extra requirements for the product design, development process, production process or maintenance, i.e. the complete product life cycle.
Warning
All makes/brands and types of directional control valves – inclusive proportional valves – can fail and cause serious damage. It is therefore important to analyze all aspects of the application.
Because the proportional valves are used in many different operation conditions and applications, the manufacturer of the application is alone responsible for making the final selection of the products – and assuring that all performance, safety and warning requirements of the application are met.
The process of choosing the control system – and safety levels – is governed by the machine directives EN 13849 (Safety related requirements for control systems).
520L0247 • Rev JA • May 2014 7
Service Manual PVG 120 Proportional Valve Group
Safety in application

Control system example

Example of a control system for manlift using PVE Fault monitoring input signals and signals from external sensors to ensure the PLUS+1® main controllers correct function of the manlift.
Legend:
1 – Main power supply 2 – Emergency stop/man present switch 3 – HMI/Joystick control 4 – Movement detection sensors 5 – Main controller 6 – PVG control valve 7 – Hydraulic deactivation
8 520L0247 • Rev JA • May 2014
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Service Manual
Safety in application
PVG 120 Proportional Valve Group
Electrical block diagram for the above illustration
Warning
It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.
PVG 32 – mainly used in system with fixed displacement pumps:
•
PVSK, commonly used in crane application - full flow dump
•
PVPX, LS dump to tank
PVG 100 – alternative LS dump or pilot supply disconnect:
•
PVPP, pilot oil supply shut off
•
External cartridge valve connecting LS pressure or main pressure to tank
PVG 120 – pump disconnect / block for variable pumps:
•
PVPE, full flow dump for the PVG 120
•
External cartridge valve connecting LS pressure to tank
520L0247 • Rev JA • May 2014 9
Fault detection output
high=on low=off
Alarm
logic
2)
Memory3)
E1
E2
Output
AND
OR
U
DC2
Error
U
S
Neutral detection / Supply control
signal ≠ neutral
OFF
Delay
1)
U
DC2
Error
U
S
PVEH
with AMP connector
PVEH
with AMP connector
Hydraulic
deactivation
Neutral detection / Supply control
signal ≠ neutral
OFF
Delay
1)
PVE 1
PVE 2
Emergency
stop
Man present
switch
C
C
D
B
B
A
P301 318
W
Service Manual
Safety in application
PVG 120 Proportional Valve Group

Examples of wiring block diagram

Example of a typical wiring block diagram using PVEH with neutral power off switch and fault monitoring output for hydraulic deactivation.
A– Emergency stop / man present switch B– PVE Fault monitoring signals C– Neutral signal detection. D– Hydraulic deactivation
System Control Logic e.g. PLUS+1® for signal monitoring and triggering signal for deactivation of the hydraulic system.
Warning
It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.
10 520L0247 • Rev JA • May 2014
Neutral detection / Supply control
signal ≠ neutral
OFF
Delay
1)
Fault detection output
PVEH-DI
AMP supply
connector
PVEH-DI
AMP supply
connector
PVEH-DI
AMP connector
PVEH-DI
AMP connector
AND
high=on low=off
Neutral detection / Supply control
signal ≠ neutral
OFF
Delay
1)
PVE 1
PVE 2
Fault detection
Delay
DI
Logic
Memory
U
S
DI-A
DI-B
2)
4)
3)
Output
Fault detection
Delay
DI
Logic
Memory
U
S
DI-A
DI-B
2)
4)
3)
Output
OR
Emergency
Stop
Man present
switch
P301 319
U
DC2
Error
U
S
DI-B
Error
DI-A
U
DC2
Error
U
S
Error
DI-A
Hydraulic
deactivation
W
Service Manual
Safety in application
PVG 120 Proportional Valve Group
Example of fault monitoring for deactivation of the hydraulic system with extra fault inputs using the PVE’s with DI (Direction Indication) function.
System Control Logic e.g. PLUS+1® for signal monitoring and triggering signal for deactivation of the hydraulic system.
Warning
It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.
520L0247 • Rev JA • May 2014 11
PVMD
PVH
F
D
C
PVP
PVM
PVB
PVT
E
G
PVEO
PVEH
S
MA
P
PVM
V310156.A
Service Manual

Identification

Identification

PVG 120 Proportional Valve Group
PVG 120 Identification
C: PVG – number, week and year of installation D: PVP – pressure setting E: PVP – number, week, year and day manufacturing, issue and series No. F: PVB – A-Port, number, week, year and day manufacturing, issue and series No. G: PVT – week and year of manufacturing
12 520L0247 • Rev JA • May 2014
60 Nm [530 lbf•in]
60 Nm [530 lbf•in]
190 [7.48]*
100 [3.94]*
190 [7.48]*
100 [3.94]*
105 [4.13]
L
4xM12x18 [4x7/16-14UNCx0.7]
V310179.A
Service Manual
PVG 120 Proportional Valve Group

Installation

Installation and plug orientation

Installation Dimensions
* Room for dismantling
Module of PVB 1 2 3 4 5 6 7 8
L mm 168 235 302 369 436 503 570 637 L in 6.61 9.25 11.88 14.53 17.17 19.80 22.44 25.08

Connection, PVP, Pump Side Module

520L0247 • Rev JA • May 2014 13
A
B
P B
V310169.A
A
P A
PA
PB
P
B
V310163.A
A
B
P B
V310162.A
A
P A
PA
PB
P
B
V310170.A
Service Manual PVG 120 Proportional Valve Group
Installation

Oil flow direction

Mechanical / electrical actuation Mechanical / hydraulic actuation

Tightening Torques

Max. tightening torques – Connection Threads Type G (ISO 228/1)
Max. tightening torques
Ports PA, PB MA LS, LX, PP
Sealing thread G 1/4 G 1/4 G 3/8 With steel washer 35 N•m [310 lbf·in] 40 N•m [350 lbf·in] 60 N•m [530 lbf·in] With cooper washer 30 N•m [270 lbf·in] 20 N•m [180 lbf·in] 35 N•m [310 lbf·in] With aluminium washer 30 N•m [270 lbf.in] 30 N•m [270 lbf.in] 40 N•m [350 lbf·in] With cutting edge 35 N•m [310 lbf.in] 40 N•m [350 lbf.in] 60 N•m [530 lbf·in]
14 520L0247 • Rev JA • May 2014
Service Manual PVG 120 Proportional Valve Group
Installation
Max. tightening torques – Mounting Threads in SAE J 518c Flanges
Port Size Threads Tightening torque
P 1 in M12, 18 deep 68 N•m
7/16 - 14 UNC 0.7” deep [600 lbf·in]
A/B 3/4 in M10, 17 deep 45 N•m
3/8 - 16 UNC 0.7” deep [400 lbf·in]
T 1 in M10, 17 deep 45 N•m
3/8 - 16 UNC 0.7” deep [400 lbf·in]
Max. tightening torques – UN and UNF Connection Threads – O-ring Boss Port
Max. tightening torques
Ports P A/B T PA/PB MA LS, LX, PP
Sealing /Thread
O-ring 160 N•m 120 N•m 160 N•m 30 N•m 30 N•m 60 N•m
1 5/16 in-12 UN 1 1/16 in-12 UN 1 5/16 in-12 UN ½ in-20 UNF ½ in-20 UNF ¾ in-20 UNF
[1410 in•lbs] [1060 in•lbs] [1410 in•lbs] [270 in•lbs] [270 in•lbs] [530 in•lbs]
Ports identification
520L0247 • Rev JA • May 2014 15
37.5˚
67.5˚
97.5˚
127.5˚
157.5˚
187.5˚
19.5˚
19.5˚
V310018.A
22.5˚
52.5˚
82.5˚
112.5˚
142.5˚
172.5˚
19.5˚
19.5˚
V310014.A
10[0.39]
8 Nm
-
+
+
-
B
A
max.B
[70 lbf in]
LX
T
PP
3[0.12]
Q
Q
max.A
max.Qmax.
Q
max.B
Q
max.A
Q
V310101.A
Service Manual PVG 120 Proportional Valve Group
Installation

PVM, Lever Positions

Base with an angle of 37.5° Base with an angle of 22.5°

Setting of max. flow

Setting of Max. Flow
16 520L0247 • Rev JA • May 2014
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